AutoStore Systems: Designing in Employee Safety
AutoStore has become one of the most efficient automated storage and retrieval systems (AS/RS) on the market — and for good reason. Its modular grid design, robotic picking technology, and high-density storage capabilities make it a go-to solution for high-volume fulfillment operations. But even the most advanced automation still relies on people. Where people work at elevation, fall protection isn’t optional.
Elevated platforms and mezzanines are frequently used to allow maintenance equipment, robots, and materials to be delivered into and out of the system. These platforms need to accommodate pallet drops, equipment transfers, and routine access — all of which create fall and dropped-load hazards if left unprotected.
We design safety gate systems for elevated platforms and workstations, which includes AutoStore environments. We know the time to design fall protection in is before the facility environment is complete. Being proactive ensures the safety in in place, the safety gate is sized correctly and it seamlessly integrates within the system before employees begin work. Safety gates can be retrofit after the AutoStore system is running, but it’s better to be proactive with your employee protection.
Elevated Ports in AutoStore Systems
AutoStore handles most of the picking automatically, but employees remain a critical part of the operation. Workers stationed at ports — the designated workstations where robots deliver totes — are responsible for order fulfillment and stock replenishment. When those ports are located on elevated mezzanines or platforms, the edge becomes a serious hazard.
Our dual-gate mezzanine safety systems are purpose-built for these applications. The logic is straightforward: when the ledge gate is open to receive material, the interior gate is closed, keeping the worker back from the edge. Once the port is loaded and the ledge gate closes, the worker can safely access the material. At no point is the employee exposed to an unguarded edge.Designing safety into the AutoStore project from the beginning ensures everything fits — the platform dimensions accommodate the gate, the gate accommodates the equipment, and the control integration is planned rather than patched. The result is a safer, cleaner installation that works the way it was meant to.
We work with integrators and facility planners early in the process specifically for this reason. Reach out to our team before your next AutoStore project goes to design. We’ll make sure the safety systems are sized, specified, and integrated from day one.
